[PDF] - 4/2/2012 AN INCONVENIENT TRUTH Courtesy : Dr. A. Kader Bad cold PDF Document

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AN INCONVENIENT TRUTH

Bad cold chain practices at every level Customer (The ultimate sufferer) Courtesy : Dr. A. Kader

THE NEED & NECESSITY Cold Storage Development For Perishables Treat a commodity like human being

Courtesy : Dr. A. Kader

WHAT IS THE EXISTING SITUATION

Not efficient / Attempting efficiency – Cold Chain

Practice.

Voluminous produce – limited availability
Quality not so good always
Set back to Growers – imports
Product Wastage on field
Not proper / efficient storage

IMPROPER COLD STORAGE

INSULATION PURPOSE

Initially

when Cold Storage starts, Refrigeration equipment brings down temp.

Subsequently insulation maintains

the temperature.

The basic rules for insulation system are :



Using good insulating material having a high insulating value, characterized by a low thermal conductivity



Protection to the insulant against vapour ingress, by providing a Vapour Retarder applied directly to the wall to restrict migration

f

ambient atmospheric moisture into the cold room interior.

Plaster+Brick+Plaster+VB+Insulation+Finish

Approx. 360mm wall



Use an interior lining on insulation essentially to prevent mechanical damage

Brick wall

Bitumen

CONVENTIONAL COLD STORE

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EXISTING COLD STORE – PROBLEMS, CONVENTIONAL PRACTICE Brick wall

Bitumen

Sequential application of vapor barrier, insulation & plaster finish What about moisture ingress from inside & life of plaster finish Basic Thermal & Civil

Engg. Design problem

EXISTING COLD STORE – PROBLEMS

CAUSES OF THERMAL INSULATION SYSTEM FAILURE

Continuous moisture ingress

through plaster

Insulation

becoming wet & resistivity decreases

Plaster chipping off
Vapour barrier becomes weak
Formation of cold spots
Deterioration

& failure

f

Thermal Insulation System

1 % OF MOISTURE INGRESS = 5 % REDUCTION IN ‘R’ VALUE

DOUBLE MOISTURE ATTACK

9

EXPANDED POLYSTYRENE (EPS) TECHNICAL SPECIFICATIONS

DENSITY

18 to 22 kg/m3. Higher densities available on request

Temperature range

200 deg.C to 80 deg.C

Thermal conductivity

The air entrapped within the minute closed cells impart to

the material its extraordinarily low thermal conductivity 0.314 W/mK at 100C mean temp. Compressive Strength

0.7 to 1 kg/m2 at 10% deformation

Cross Breaking Strength 1.4 to 1.8 kg/m2 Water Absorption (after 24 hrs. immersion)

Less than 0.5% by volume

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EXPANDED POLYSTYRENE (EPS) TECHNICAL SPECIFICATIONS

Chemical Inertness

Unaffected by water, acids, alkalies, alcohols and most oils of

vegetable and animal origin. Soluble in aliphatic, aromatic and chlorinated hydrocarbons, ketones, esters, ethers, petrol, turpentine, concentrated sulphuric and nitric acids Handleability

Easily cut with a knife and readily applied with solvent free bitumen

and adhesive Standard Sizes

Slabs – 1M x ½ M of thickness 25mm to 100mm

Pipes – ½M length of thickness 15 to 150mm Other sizes and thicknesses available on request. Draw backs

Moisture gets entrapped between cells and ice formation, leads to

failure gradually.

Low density
Poor compressive strength
Poor adhesion
Lower temp. rating

INSULATION LIFE

Insulation needs to be properly fixed to surface
Insulation needs to be covered & protected
Cold Insulation needs vapour barrier on warm side
Cold storage Insulation needs vapour

barrier on both sides to counter moisture attack on both sides.

Thermal Engineering issue

Suppose if Insulation is changed

Changing from Open Cell Structure to Closed Cell Insulation materials

Polyurethane Foam Slabs with

aluminium foil

Cold adhesives
Proper Thickness (70 ->85-

90% RH)

PPGI sheet finish
Polymerized plaster

Brick wall

Thermal insulation

Vapour Barrier Supporting Structure PPGI Sheet Overlapping joints

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Suppose if Insulation is changed

Jointing problem will persist.
PPGI sheet finish, conduction losses from back

up support / cold spots

Moisture ingress thru joints.
Labour intensive application.
Partial solution
Poor aesthetics

 Polymerized plaster & PUF

Basics

Polyurethane & Polyisocyanurate Foams :

Manufactured out of a very fast chemical exothermic

reaction between two chemicals in presence of a blowing agent resulting into a polymer matrix & gas filled closed cells all around

Basics

Gas filled air cells has very low conductivity which

reduces heat conduction

Smaller size of cells reduces convection
Every cell acts as a barrier to radiative heat loss
Some air does enter the blowing agent cells and fills

up thru aging

Thermal conductivity slightly changes – aging (0.017

to 0.021 W/mK)

High Performance Closed Cell Insulation Material

Polyurethane & Polyisocyanurate Foams -
Lowest thermal conductivity (0.021 W/mK)
Adequate density (32-36 kg/m3 for Slabs, 40-45

kg/m3 for panels)

Higher temperature rating (110-140 deg.C)
Higher Resistance Values
CFC, HCFC & ZERO ODP
Low embodied energy
Indigenously manufactured (within 500 kms. any site)
Green Insulation – 5 Points

Basics

Extruded Polystyrene Foams :

Light Petrochemical beads / globules compressed &

cured with steam

Expanded has permeable faces & Extruded partially /

easily damageable impermeable faces

Lower temperature ratings 700C (max.)
Higher manufacturing / embodied energy
Low density
Extruded still primarily imported
Primarily cold climate product

18 18

UPGRADED INSULATION SYSTEM

1) Masonry 2) Adhesive 3) Polyurethane/PIR Foam 4) Basecoat 5) Fiber mesh 6) Top Coat

ETICS : Upgrade conventional insulation practice

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1. External Plaster 2. Bricks 3. Special adhesive for PUF 4. PUF Insulation slab 5. Polymerized Plaster or Tile

UPGRADED INSULATION SYSTEM Insulation applied on Wall Existing Cold Stores

Direct application of PUF insulation on plastered

walls from inside or outside.

Polymerized Plaster with reinforcement.
Painting

Existing Cold Stores with sound civil construction – Revamping of Insulation

WALL INSULATION WITH PUF / PIR SLABS APPLICATION OF PRIMER COAT

REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF / PIR SLABS APPLICATION OF ADHESIVE

REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF / PIR SLABS APPLICATION OF ADHESIVE

REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF / PIR SLABS FIXING OF SLAB ON TO THE WALL

REVAMPING OF EXISTING COLD STORES

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REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF / PIR SLABS FIXING OF SLAB ON TO THE WALL WALL INSULATION WITH PUF / PIR SLABS STAGGERED JOINTS

REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF / PIR SLABS APPLICATION OF BASE COAT

REVAMPING OF EXISTING COLD STORES

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WALL INSULATION WITH PUF / PIR SLABS APPLICATION OF BASE COAT

REVAMPING OF EXISTING COLD STORES

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WALL INSULATION WITH PUF / PIR SLABS FIXING OF REINFORCEMENT MESH

REVAMPING OF EXISTING COLD STORES

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WALL INSULATION WITH PUF / PIR SLABS FIXING OF REINFORCEMENT MESH

REVAMPING OF EXISTING COLD STORES

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WALL INSULATION WITH PUF / PIR SLABS APPLICATION OF TOP COAT

REVAMPING OF EXISTING COLD STORES

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REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF/PIR (EXTERNAL) FINAL FINISH

REVAMPING OF EXISTING COLD STORES

WALL INSULATION WITH PUF/PIR (EXTERNAL) FINAL FINISH

Insulation applied inside Existing Cold Stores

Direct application of PUF insulation on plastered

walls from inside.

Polymerized Plaster with reinforcement.
Painting

Existing Cold Stores with sound civil construction – Revamping of Insulation

What is the Solution to achieve efficiency in Cold Store construction

MODERN PRACTICE IN COLD STORE CONSTRUCTION

Brick wall

Bitumen Total thickness: 360mm Replaced with Thickness 80 to 100/ 150 mm. PUF Panels

Conventional

Modern

Moist/Wet

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DESIGN TREND IN MODERN COLD STORES

MATERIALS :

Prefabricated Polyurethane Foam sandwich panel
Metal sheet finish – solid barrier on both sides
Energy efficient insulation
Scientifically designed edges, camlocks
Steel Structure / PEB

MODERN COLD STORE

1. PUF Panel 2. Metal facing

MODERN COLD STORE MODERN COLD STORE

Modular Cold Store

DESIGN TREND IN MODERN COLD STORES

ADVANTAGES :

Thermal & vapour barrier metal finish panels
Easy to install
Less labour intensive
Fast construction
Energy efficient
In practice in India since 1994 / 97

Modern practices in cold store construction

Pre-engineered – Prefab Construction

Fire Safe

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Modern practices in cold store construction

 RCC work is replaced by steel columns and purlins – a Pre-engineered Building Technology.  Brick walls & Insulation, False Ceiling with Insulation replaced by Polyurethane Sandwich panels directly fixed to the columns.  4-6 tiers can be formed of height 7 feet each.  Maintaining an air gap of 1-2 feet on the sides and 4 feet for stair case.

Modern practices in cold store construction

Wall insulation is 80mm thick Rigid Polyurethane Foam Panel, with 0.5mm thick Colour Coated and Galvanized Sheet on both sides, with Tongue & Groove jointing detail and cam-lock arrangement. Ceiling Panels are 100mm thick. Floor is 60mm EPS as in Conventional System

r PUF slabs

Rain Guard profile sheet Insulated doors Energy Efficient Refrigeration system Panel Dimensions Length : 12 mtr. (max.) Width : 0.6 – 1.2 mtr. Thickness : 50,60,80,100,120,150,200mm Shape : Straight L shape for corners Lloyd Panel System- Prefab Panels

Modern practices in cold store Features

ELEMENTS OF A MODERN COLD STORE

PEB Steel structure framing

PRE-ENGINEERED BUILDING STRUCTURE

PEB frames are tapered and flanges and webs often have variable thickness.
The frame geometry matches the shape of the internal stress diagram, thus

minimizing material waste and reducing the total weight.

Green Building Structure

Built-Up Section

PRE-ENGINEERED BUILDING STRUCTURE

Built-Up Section Purlin & Girt Sheeting Panel

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PRE-ENGINEERED BUILDING STRUCTURE PRE-ENGINEERED BUILDING STRUCTURE

Panels with both side metal

facing acting as impermeable vapour barriers

Avoids

moisture coming in contact with insulation

No deterioration of insulation
Joints between panels sealed
Moisture remains always over

metal sheet

Equilibrium situation leading to

Energy Conservation

CFC & HCFC free, zero ODP,

cyclo Pentane blowing

Length upto 12 mtr.
Green Panels – 5 Points

Camlock option

LLOYD PANEL SYSTEM PREFAB SANDWICH PANELS

Automatic Plant
Environment friendly
Contimat

LLOYD PANEL SYSTEM Mechanical product handling PANEL MANUFACTURING

Continuous Spray of Polyurethane Foam

PANEL MANUFACTURING

DISCONTINUOUS CAMLOCKS

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Strict Quality

Control

Inhouse Lab

LLOYD PANEL SYSTEM

THERMAL & LOAD CHARACTERISTICS OF PANEL

Thickness mm 60 80 100 120 150 200 ‘U’ value w/m2k 0.36 0.26 0.21 0.19 0.14 0.11 Panel weight Kg/m2 11.25 12.05 12.85 13.65 14.85 16.85

LLOYD PANEL SYSTEM PREFAB SANDWICH PANELS LLOYD PANEL SYSTEM PREFAB SANDWICH PANELS

Properties of polyurethane foam

DENSITY 40+ 2 kg/ m3. Compressive strength At 10% deformation 2.1 kg/cm2 Tensile strength 3.7 kg/cm2. Bending strength 4.0 kg/cm2. Adhesion strength (Foam to steel) 2.9 kg/cm2. Dimensional stability (48hrs)

25 DegC

+38 Deg.C & 90 % RH +100 Deg.C 0.1% 0.1% 0.4% Closed cell content 90-95% Temperature range

180Deg.C to +110 Deg.C

CFC & HCFC FREE, ZERO ODP, CYCLO Pentane

Properties of polyurethane foam

Thermal conductivity at 10 Deg. C

0.020k-cal/m-hrdeg.C or 0.023 W/mK

Fire resistance Horizontal extent of burn BS 4735 <125mm. Self extinguishing ASTM D 1692

(fire retarded foam chemical) Not easily ignitable as per BS 476 pt.5 & class 1 as per BS 476 pt.7 (for panel)

Passes Water absorption 0.2% volume at 100% RH Water vapour permeability (at 90%RH & 38Deg.C) 0.08-0.12 gms/hr m2 CFC & HCFC FREE, ZERO ODP, CYCLO Pentane

LLOYD PANEL SYSTEM PREFAB SANDWICH PANELS

LOWEST THERMAL CONDUCTIVITY GREEN POINTS : 5

MODERN PRACTICES IN COLD STORE CONSTRUCTION Main features of Lloyd Panel System –

A high strength to weight ratio, with significant

savings in steel work and load bearing foundations, allowing large spans to be constructed with no intermediate columns.

Dimensional stability.
Maintenance-free surface.
High

thermal efficiency ensures low heat transmission, resulting in lower refrigeration load.

No deterioration of thermal efficiency over time.
Panels can be furnished in single jointless height /

Length upto 12 mtrs. Partition wall can be easily erected as the panels are self supporting.

MODERN PRACTICES IN COLD STORE CONSTRUCTION Main features of Lloyd Panel System –

To arrest thermal leakage, joints are finished in tongue

and groove configuration which in combination with

ptional CAMLOCKS ensures a foam to foam joint

rather than a metal to metal joint.

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MODERN PRACTICES IN COLD STORE CONSTRUCTION Main features of Lloyd Panel System –

Panel system incorporates special “L” shaped single

piece panels for CORNERS. This avoids wall to wall direct jointing - provides additional stability, strength, aesthetical appearance, easy house keeping etc.

For additional reinforcement “U/L” shaped flashing are

provided at wall to ceiling joints.

Rain guard profile sheet over ceiling panels

MODERN PRACTICES IN COLD STORE CONSTRUCTION Main features of Lloyd Panel System –

Proven in Indian conditions since 1994 & widely

available - 20 million SQM per Annum

MODERN PRACTICES IN COLD STORE CONSTRUCTION

INSTALLATION PROCEDURE

Structure, Panels

MODERN PRACTICES IN COLD STORE CONSTRUCTION

INSTALLATION PROCEDURE

Ceiling, Wall, Floor Orientation

MODERN PRACTICES IN COLD STORE CONSTRUCTION WALL – CEILING CONNECTION

1. Outer Corner Profile
2. Inner Corner Profile
3. Sealant

MODERN PRACTICES IN COLD STORE CONSTRUCTION WALL – CEILING CONNECTION

1. Outer Corner Profile
2. Inner Corner Profile
3. Sealant

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MODERN PRACTICES IN COLD STORE CONSTRUCTION

Covings

Special arrangement

MODERN COLD STORAGE

VERTICAL FIXING OF PANELS

MODERN COLD STORE

Lifting of panels for Wall

MODERN COLD STORE

Panel External Wall

Max. single length 12M generally

MODERN COLD STORE

Panel External Wall

Max. single length 12M generally

MODERN COLD STORAGE

PANEL FIXING ON FLOOR WITH CHANNEL

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MODERN COLD STORE

1. PUF Panel 2. Steel Purlin

MODERN COLD STORAGE

INSIDE VIEW

MODERN COLD STORAGE

INSIDE VIEW

MODERN PRACTICES IN COLD STORE CONSTRUCTION

Panel Partitions

Multi Chambered Cold Stores

MODERN PRACTICES IN COLD STORE CONSTRUCTION

Wall Construction details with Panels

MODERN COLD STORAGE

WALL PANELS ERECTED

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MODERN PRACTICES IN COLD STORE CONSTRUCTION Roof Construction details with Panels

ENGINEERING DETAILS

MODERN PRACTICES IN COLD STORE CONSTRUCTION

Ceiling Panel

Panel to Hanger orientation

MODERN PRACTICES IN COLD STORE CONSTRUCTION CEILING SUSPENSION SYSTEM

3. Sealant
7. PUR Injection
15. Purlin
16. Truss
17. Ø 10 Hanger Tiege
18. Adhesive Tape
19. Cover Profile
20. Suspension Profile

MODERN COLD STORAGE

FIXING OF CEILING PANELS

MODERN PRACTICES IN COLD STORE CONSTRUCTION Ceiling Panel

MODERN PRACTICES IN COLD STORE CONSTRUCTION

Floor Construction details

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MODERN PRACTICES IN COLD STORE CONSTRUCTION

Floor Construction details

MODERN PRACTICES IN COLD STORE CONSTRUCTION WALL FLOOR CONNECTION

3. Sealant
4. L Profile
5. Bottom Border Profile
6. Plain Concrete For Slope
7. Protective Concrete
8. Reinforced Concrete
9. Floor Water Insulation
10. Floor Heat Insulation
11. Lean Concrete

MODERN PRACTICES IN COLD STORE CONSTRUCTION WALL FLOOR CONNECTION

2. Inner Corner Profile
4. L Profile
8. Reinforced Concrete
9. Floor Water Insulation
10. Floor Heat Insulation
11. Lean Concrete
Rain Guard Profile Steel Sheet
Exhaust Fan

MODERN PRACTICES IN COLD STORE CONSTRUCTION

COLD STORAGE CONSTRUCTION Colour Coated GI Sheet Rain Guard

VARIETY OF DOORS HINGE & SLIDING

MODERN COLD STORE

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CA DOORS

MODERN COLD STORE

MOTORIZED DOORS

MODERN COLD STORE SAFETY - FIRE SAFE PANELS

Classified under Class-1 Construction
Classified as Not Easily Ignitable according to BS :

476 Part-5

Surface Spread of Flame Classification determined as

Class-1 according to BS : 476 Part-7 MODERN COLD STORE Environment Friendly

Zero ODP PUF
CFC, HCFC Free Rigid Polyurethane Foam
Steel finish

MODERN COLD STORE HYGIENE

Panels does not allow growth of any Biological item
Corners have flashings /covings to stop any dust

deposition

Panels are washable

MODERN COLD STORE

REFRIGERATION LIGHTING SYSTEM

MODERN COLD STORE

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MODERN COLD STORE INTERIOR

MODERN COLD STORAGE

COMPLETED PROJECT GREEN COLD STORAGE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

PEB STRUCTURE, PANEL, DOOR MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

PEB STRUCTURE, PANEL, DOOR MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

RAFTER & PURLINS MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

RAFTER & PURLINS MULTI PRODUCT MULTI CHAMBERED COLD STORE

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MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

ROOFING SHEET OVER PURLINS – RAIN GUARD MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

PANEL JOINTING MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

CORRIDOR MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

CORRIDOR MULTI PRODUCT MULTI CHAMBERED COLD STORE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

VEHICLE PARKING

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

VEHICLE PARKING

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MULTI CHAMBERED CORRIDOR

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

RACKING

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

PRODUCT STORAGE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

FIXING OF HORIZONTAL PANEL FROM INSIDE

CA STORAGE

PANEL ERECTION PROCEDURE HORIZONTAL FIXING TO COLUMNS FROM OUTSIDE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

HORIZONTAL PANEL ERECTION PROCEDURE

MODERN PRACTICES IN COLD STORE CONSTRUCTION – CONTRACTING

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PEB & Panel erection complete Green Cold Storage

MODERN COLD STORE CONSTRUCTION

PEB & Panel erection complete Green Cold Storage

MODERN COLD STORE CONSTRUCTION

OFFICE SPACE COLD STORE SORTING GRADING

MODERN COLD STORE CONSTRUCTION

PEB & PANELS IMPRESSIVE FINISH & FAST CONSTRUCTION

MODERN COLD STORE CONSTRUCTION

PEB & PANELS, RCC COLUMNS

MODERN COLD STORE CONSTRUCTION

PEB & PANELS LARGE CLEAR SPAN

MODERN COLD STORE FEATURES

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MODERN COLD STORE FEATURES

LARGE INTERIOR SPACE

PROPER UTILIZATION OF SPACE

MODERN COLD STORE FEATURES

POTATO COLD STORAGE CLEAN INTERIORS

MODERN COLD STORE FEATURES MODERN COLD STORE FEATURES PROPER AIR FLOW

CHILLED WATER INSULATED PIPES WITH PVC CLADDING

MODERN COLD STORE FEATURES COLD STORAGE CONSTRUCTION

2009

COLD STORE OVER EXISTING RCC BUILDING COLD STORES

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COLD STORAGE CONSTRUCTION

PEB & Panels

ver RCC

Building

COLD STORAGE CONSTRUCTION COLD STORAGE CONSTRUCTION Long Height Corridor COLD STORAGE CONSTRUCTION Corridor & Multi Level Doors COLD STORAGE CONSTRUCTION Flooring COLD STORAGE CONSTRUCTION Ceiling Panels

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COLD STORAGE CONSTRUCTION Ceiling Panels COLD STORAGE CONSTRUCTION Chilled Water Piping COLD STORAGE CONSTRUCTION Chilled Water Pipe Support COLD STORAGE CONSTRUCTION Chilled Water Pipe Insulation COLD STORAGE CONSTRUCTION Chilled Water Pipe Insulation

PRE-INSULATED PIPE

COLD STORAGE CONSTRUCTION

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Less labour intensive & fast construction technology.
More interior space.

MODERN COLD STORE CONSTRUCTION

Panel Erection Inside Warehouse

MODERN COLD STORE CONSTRUCTION CLEAN ROOM MODERN PRACTICES IN COLD STORE FEATURES

Food Processing

Chambers made from PUF Panels

MODERN PRACTICES IN COLD STORE FEATURES

Food Processing

Chambers made from PUF Panels

COLLECTION CENTRE STORES

Small stores
Prefab Panels
5-7 degree temperature drop
With or without cooling
Exhaust fan

Field Store

TRANSPORTATION

REFRIGERATED VAN

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TRANSPORTATION

STRUCTURE – FRAMEWORK - PANELS REFRIGERATED VAN

TRANSPORTATION

REFRIGERATED VAN INSULATED DOORS

TRANSPORTATION

REFRIGERATED VAN RUBBER GASKET SEALING

TRANSPORTATION

REFRIGERATED VAN STORES RUBBER GASKET SEALING

TRANSPORTATION

PLASTIC CURTAIN

TRANSPORTATION

REFRIGERATED VAN INTERIOR

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COLD STORAGE CONSTRUCTION COST

I. CONVENTIONAL COLD STORE

CAPACITY : 5000 MT a) Brick : 5 Lacs nos. @Rs.12/Brick = Rs.60 Lacs b) 4-6” EPS + 0.5 / 0.6mm TCT = Rs.60 Lacs Colour coated GI Sheet c) Total Cost : Rs. 10,000 – 12,000/MT

COLD STORAGE CONSTRUCTION COST

II. MODERN COLD STORE

CAPACITY : 5000 MT a) Panels : Rs. 115-120 Lacs b) Total Cost : Rs. 12,000 – 14,500/MT (PEB, Panels, Refrigeration, Civil, Racking, machinery etc.)

III. Difference : 20-25 %

COLD STORAGE CONSTRUCTION COST

IV. Almost same for conversion from Brick +

Insulation to panels i.e. Rs.120 Lacs

V. Total cost for 7000 tons Cold Store with RCC Roof,

RCC columns & Panels = Rs.675 Lacs {@9643/ Ton (approx.)}

COLD STORAGE CONSTRUCTION COST

CAPACITY : 7000 MT RCC Roof, RCC columns & Panels Civil : 250 Lacs Panel : 115 Lacs Land : 50 Lacs Building : 30 Lacs Racking : 50 Lacs Lighting : 80 Lacs Machinery : 100 Lacs

675 Lacs

==============

TECHNICAL STANDARDS AND PROTOCOL FOR THE COLD CHAIN IN INDIA

National Horticulture Board (Department of Agriculture & Cooperation Ministry of Agriculture, Govt. of India) 85, Institutional Area, Sector-18 Gurgaon -122015 (Haryana)

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TYPICAL LAYOUT TYPICAL LAYOUT TYPICAL LAYOUT

OPTION-1 :

Typical 5000 MT Multi Commodity Cold Store with provision of rapid room cooling and palletized storage, suitable for long / medium term storage of Fruit and Vegetables

TYPICAL LAYOUT TYPICAL LAYOUT

OPTION-2 :

Typical Multi Commodity Cold Store with provision of separate pre-cooling rooms and high humidity cold stores

Cold Chamber : 250 -1250 MT – 4 nos.
Multi Commodity chambers : 30-1250 MT
Pre-cooling chamber : 30-150 MT

TYPICAL CONFIGURATION

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CONSTRUCTION FEATURES

Super Structure Foundation : As per BIS Standards Cold Store Building : RCC OR steel structure / PEB as per IS : 875 Cold Chamber : Walls - 1. 230mm brick wall with plaster on both sides, vapour barrier insulation and profiled pre-coated GS sheet

2. Pre-fab steel structural frame work

with insulated panel boards CONSTRUCTION FEATURES

Cold Chamber : Roof - 1. RCC slab with waterproofing , proper sloping and mosaic finish.

2. Truss roof with pre-coated GS sheet with

FRP sheet provision for natural lighting and turbo ventilators or alternatively insulated roofing panels. There should be provision for fixing insulated panels from the trusses to act as False Ceiling. FRP sheet for natural lighting Floor - Base concrete with insulation & RCC finish.

CONSTRUCTION FEATURES

STEEL / PRE-ENGINEERED CONSTRUCTION

Structure as per ASTM / BIS Standards
Wall, Ceiling & partition with insulated panels of PUF,

1-1.2 mtr. Wide & length max. 12 mtr., 80mm thick.

Single piece from floor to ceiling
Held by fasteners
Joints sealed with Silicon Sealant

CONSTRUCTION FEATURES

ANTE ROOM

At least one Ante room
Sorting, grading area
Temperature range 20-24 deg.C
Mechanized sorting, grading, washing & packing
Palletization & Strapping Facility
Pallet Jack & Fork Life
Bins, Crates, Pallets and Racks
Strip curtains for cold rooms and air curtains for

external outlets / inlets

Rodent proof civil structure and proper drainage of

water to be ensured

Rooms for machines, Electrical etc.

Insulation Thickness

Minimum Insulation Thickness based on Recommended U Values for -4 to +20 Cold Storage

Type of Insulation Material Wall Ceiling / Roof U Value = 0.24 W/m2K Floor U Value = 0.29 W/m2K External U Value = 0.27 W/m2K Partition U Value = 0.58 W/m2K p Density Kg/m3 K (at 100C) W/mK Thickness mm Thickness mm Thickness mm Thickness mm EPS 15 0.036 150 75 150 125 PUF 32 0.023 100 50 100 100 XPS## 30-35 0.025 100 50 100 100 Phenolic Foam*** 50 0.026 100 50 125 100 Mineralwool*** 48 0.033 125 50 125 100 Bonded Fibre Glass / Glasswool *** 32 0.033 125 50 125 100 Panel 40+2 0.023 80 60 80 80 ***Recommended only with vapour barrier and metal or FRP cladding min. 0.5mm TCT ##Recommended in conformance to ISO/FDIS 4898:2008(E) for properties of XPS used for thermal insulation of buildings, Categories-II, III & IV only.

CONSTRUCTION FEATURES

ANCILLARY MATERIALS

Vapour barrier e.g. aluminium foil, polythene sheet,

with bitumen / cold mastic adhesives

Teakwood batten pegs, tees etc.
G.S. Sheet runners (avoid wooden batten runners)
Cladding of profiled / pre-coated G.S. Sheets 0.5 /

0.6mm thick / Fibre – glass sheets of suitable thickness

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CONSTRUCTION FEATURES

FOR CONVENTIONAL INSULATION WALL & CEILING

Primer coat followed by two layers of bitumen
Fixing aluminium foil min. 50 microns
Fixing wooden pegs at suitable intervals
Fixing two layers of insulation with staggered joints
Fixing G.S. Sheet runners over the pegs in

longitudinal & lateral directions

Fixing profiled & pre-coated G.S. sheet 0.5 / 0.6mm

thick over the runners with proper finishing of joints. Alternatively FRP sheets can be used

CONSTRUCTION FEATURES

FOR CONVENTIONAL INSULATION FLOOR

Laying of polythene sheet, min. 250 microns as

vapour barrier

Fixing insulation slabs in two layers with bitumen as

adhesive for the first layer

Covering with tar felt
Laying PCC / tremix of 75mm / 100mm thickness.

CONSTRUCTION FEATURES

FOR INSULATED PANEL STRUCTURE WALLS & CEILING

Perimeter of the plinth to be in level for panel

installation

Panels to have cam lock or tongue & groove joints
Sheet metal flashing to be provided on all concrete,

curbing to be provided on wall – floor joints

Horizontal tie bracings to be provided between vertical

wall panels & external columns, to take care of wind loads

Adequate numbers of pressure relief ports to be

provided on all chambers with electrical connection

Insulated doors shall be suitable for panel mounting

NHB OPERATIONAL GUIDELINES

CAPITAL SUBSIDY FOR NEW CONSTRUCTION / EXPANSION/ MODERNIZATION OF COLD STORAGES Components : Cold Stores, CA, MA, Pre-cooling Units Capacity : Up to 5000 MT Amount : 40% of capital project cost in general areas 55% in case of Hilly & scheduled areas For Storage capacity of 5000 MT

NHB OPERATIONAL GUIDELINES

GENERAL CONDITION

1. Multi Chamber Cold Storages with Mezzanine

floors of RCC or wooden structure, without precooling, 0-160C or above, RH 80-95%, 65-70% for Onion & Garlic, min. 2 chambers, standard insulation, cooling system, safety devices. Construction cost basis

Rs. 6000 per MT

NHB OPERATIONAL GUIDELINES

GENERAL CONDITION

2. Multi Chambered & Multi Product Cold Storage, without

precooling system, -2 to 160C, RH 80-95% general F&V, 65-70% for Onion & Garlic, energy saving devices, heat exchanger with CO2 control, control of micro organism, mechanical handling – fork lifts, safety devices. a) Civil / Prefab engg. structure, insulation, cooling as per standards excluding mezzanine

Construction cost basis

Rs. 7000 per MT

b) Civil / prefab engg. structure, insulation, cooling as per standards excluding mezzanine, having pack house facilities (sorting, grading, wax in, packing)

Construction cost basis

Rs. 8000 per MT

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4/2/2012 30

NHB OPERATIONAL GUIDELINES

GENERAL CONDITION

3. Modernization of Cold Stores

a) Upgradation of Thermal Insulation b) Upgradation of cooling system, safety devices, electricals Rs.1000/MT for Multi chambered Cold Stores with mezzanine floor Rs.2000/MT for Multi chambered multi product with prefab engg. and with or without pack house

NHB OPERATIONAL GUIDELINES

GENERAL CONDITION

4. CA Storages : Rs.32000/MT (cost basis)
5. Should meet NHB Standard norms
6. In case of varying technical specifications a

committee will decide

THERMAL INSULATION

Procedure - As per IS : 661 Materials : a) Expanded Polystyrene b) Rigid Polyurethane Foam c) Rigid Phenolic Foam d) Mineralwool / Glasswool e) Extruded Polystyrene Thermal Insulation for Refrigerated Piping : EPS, PUF, Nitrile Rubber

THERMAL INSULATION

Vapour Barrier : Aluminium Foil, Polythene Sheet Bitumen Cold Adhesive Mastic for insulated panel structure.

Pre-fabricated panels with cam lock or Tongue & Groove joints.

IS : 661

Thermal Insulation of Cold Storage – Code of Practice (4th Revision of IS : 661)) (ICS No.27.220; 91.120.10)

IS : 661

THERMAL INSULATION MATERIALS

Expanded Polystyrene
Polyurethane / Polyisocyanurate Foam
Fibrous material
Polyurethane sandwich Panels

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4/2/2012 31

IS : 661

IMPORTANT CHARACTERISTIC OF A COLD STORAGE INSUALTION a) Low Thermal Conductivity (K) b) Lower Thermal Diffusivity (d) c) High Thermal Resistivity (R) d) Stability at low temperature

IS : 661

IN-SITU APPLICATION

Insulation of Concrete / Masonry Walls finished with Plaster.

Cleaning of the surface
Application of primer and vapour barrier layer
Fixing of wooden batten and 40mm wide and equal to

insulation thickness suitably placed,

Providing insulation in multi layer (single layer 50mm with

joints staggered)

Application of wire netting and fixed with galvanized U nails
Application of cement plaster
Floor insulation shall be with bituminous water proofing,

insulation slab, bituminous kraft paper and concrete.

IS : 661

Additional vapour barrier on inner side may also be used

IS : 661

Insulated doors comprising of well designed frames, hinges, seals ad locking devices. Doors made from PU panels complete with all fixtures.

IS : 661

PANEL APPLICATION

Main structure of Steel / RCC frame or Brick
PU Panels are directly mechanically fastened to the

Steel or RCC structure frame

Incase of brick wall, one side paper laminated panels

to be mechanically fastened.

Panel joints sealed with silicon sealant.
Floor insulation with PUF slabs.
Ceiling insulation – PU Panel shall be placed on

insulated T-beams hung from trusses.

IS : 661

Fixing detail of PU Panel on Wall & Partition Wall

SLIDE 32

4/2/2012 32

IS : 661

Fixing detail of PU Panel on Floor

IS : 661

Fixing detail of PU Panel on Ceiling

IS : 661

Sl. No. (1) Characteristics (2) Rigid Polyisocyanurate Foam (PIR) (3) Rigid Polyurethane Foam (PUF) (4) Rigid Phenolic Foam (5) Expanded Polystyrene (EPS) (6) Bonded Rockwool (7) Bonded Glasswool (8) i) Relevant IS Code IS : 12436 IS : 12436 IS : 13204 IS : 4671 IS : 8183 IS : 8183 ii) Useful forms Slabs & pipe sections Slabs & pipe sections Slabs & pipe sections Slabs & pipe sections Slabs & pipe sections Slabs & pipe sections iii) Density, kg/m3 30-38 34-38 32-60 15-35 Slab – 48 P/S – 144 Slab – 32 P/S – 80 iv) Thermal Conductivity at 100C, W/mK 0.023 at 32 kg/m3 0.023 at 36 kg/m3 0.026 at 50 kg/m3 0.037 at 15 kg/m3 0.033 at 48 kg/m3 0.033 at 32 kg/m3 v) Thermal diffusivity, m2h 0.0018- 0.0024 0.0018- 0.0024 0.0016- 0.0029 0.0037- 0.0078 0.0006- 0.0018 0.0011- 0.0027 vi) Water vapour transmission rate, ng/Pa.sm. Max. 5.5 5.5 5.5 7.95

vii)

Water absorption after 24 h immersion, percent by mass 0.1 0.1 0.1 1.0 2.3 2.3

Physical Properties of Insulating Materials

IS : 661

ANNEX B ANNEX B (1) (Clause 4.2.1) THICKNESS OF INSULATION (MM) FOR DIFFERENT STORAGE TEMPERATURES WITH DESIGN AMBIENT TEMPERATURE OF 35-450C AND 70-90 PERCENT RELATIVE HUMIDITY THICKNESS FOR EXPOSED WALL

Storage Temp. Range Insulation thickness For different materials (in mm) (Calculation as per IS-3792) (DegC) PUF/PIR Phenolic foam EPS Rock wool Glass wool PUF/PIR Panel

30 to -20

120 140 200 180 180 130

20 to -15

100 110 160 150 150 100

15 to -4

90 100 150 130 130 90

4 to +2

80 90 120 110 110 80 + 2 to 10 60 60 90 80 80 60 10 to 16 40 50 70 60 60 50 16 and above 10* 10* 10* 10* 10* 10*

IS : 661

THICKNESS FOR INTERMEDIATE WALL

Storage Temp. Range Insulation thickness For different materials (in mm) (Calculation as per IS-3792) (Deg C) PUF/PIR Phenolic foam EPS Rock wool Glass wool PUF/PIR Panel

30 to -20

50 50 70 60 60 50

20 to -15

50 50 70 60 60 50

15 to -4

50 50 70 60 60 50

4 to +2

40 40 60 50 50 40 + 2 to 10 20 20 30 30 30 20* 10 to 16 20 20 30 30 30 20* 16 and above 10* 10* 20* 20* 20* 10*

IS : 661

Storage Temp. Range Insulation thickness For different materials (in mm) (Calculation as per IS-3792) (Deg C) PUF/PIR Phenolic foam EPS Rock wool Glass wool PUF/PIR Panel

30 to -20

160 180 260 230 230 160

20 to -15

130 140 210 190 190 130

15 to -4

110 120 170 150 150 100

4 to +2

90 100 150 130 130 90 + 2 to 10 80 90 120 110 110 80 10 to 16 80 90 120 110 110 80 16 and above 20* 20* 30 30 30 20*

THICKNESS FOR ROOF

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4/2/2012 33

IS : 661

THICKNESS FOR FLOOR

Storage Temp. Range Insulation thickness For different materials (in mm) (Calculation as per IS-3792) (Deg C) PUF/PIR Phenolic foam EPS Rock wool Glass wool PUF/PIR Panel

30 to -20

110 130 180 160 160 110

20 to -15

100 110 150 140 140 100

15 to -4

80 90 130 120 120 80

4 to +2

80 90 120 110 110 80 + 2 to 10 50 50 70 60 60 50 10 to 16 30 40 50 50 50 30 16 and above 10* 10* 20* 20* 20* 10*

IS : 661

ANNEX B (2) (Clause 4.2.1) Thermal & Load Characteristics of PU Panels

Thickness mm 60 80 100 120 150 200 U Values W/m2C 0.36 0.26 0.21 0.19 0.14 0.11 Panel Weight Kg/m2 11.25 12.05 12.85 13.65 14.85 16.85

IS : 661

Recommended “R & U” Value for cold storage structure

Storage Temp. Range (DegC) Maximum “R” Value (m2k/w) , “U” Value (w/m2k) Exposed walls Intermediate walls Roofs Floors R U R U R U R U

30 to -20

5.88 0.17 2.12 0.47 7.14 0.14 5.00 0.20

20 to -15

4.76 0.21 2.12 0.47 5.88 0.17 4.34 0.23

15 to -4

4.34 0.23 2.12 0.47 4.76 0.21 3.70 0.27

4 to +2

3.70 0.27 1.72 0.58 4.16 0.24 3.44 0.29 + 2 to 10 2.85 0.35 1.07 0.93 3.44 0.29 2.12 0.47 10 to 16 2.12 0.47 1.07 0.93 3.44 0.29 1.56 0.64 16 and above 0.78 1.28 0.68 1.47 0.95 1.05 0.61 1.63

IS : 661

MODERN PRACTICES IN COLD STORE CONSTRUCTION CASE STUDY (For Potato Storage) CONVENTIONAL COLD STORAGE DESIGN

Vs.

MODERN COLD STORAGE DESIGN

Storage Capacity : 6000 MT Size : 105’ (32M) x 105’(32M) x 60’(18M) (H)

MODERN PRACTICES IN COLD STORE CONSTRUCTION

CONVENTIONAL STORAGE Wall Design :

Brick Wall : 225mm (9”) Cement Plaster : 12 mm (both sides), Bituminous primer. Al-Foil (vapor barrier) : 0.05mm. (U-nails and Wooden Runners and Battens for fixing Insulation) Expanded Polystyrene : 100mm or 4” (in two layers). The final finish is a rendering of plaster ½” or 12mm. Total Wall Thickness : 360 mm.

SLIDE 34

4/2/2012 34

MODERN PRACTICES IN COLD STORE CONSTRUCTION

CONVENTIONAL STORAGE Ceiling Design Ceiling is made up in a similar manner, with EPS being 100 mm or 4” in thickness (in case of RCC Slab as roof). Floor Design Floor is insulated with 60mm EPS, after tar felting and finished with Lean Concrete (PCC) 3” (75mm).

MODERN PRACTICES IN COLD STORE CONSTRUCTION

THEORETICAL HEAT GAIN FOR CONVENTIONAL CONSTRUCTION Considering the Thermal Conductivity value for Polystyrene Foam (EPS) as 0.036 W/mK in order to allow for aging and imperfections during application for an ambient of 40-45 deg.C and operation at 4 to 6 deg.C.

MODERN PRACTICES IN COLD STORE CONSTRUCTION

CONVENTIONAL STORAGE Thermal Transmission Values Q Wall = 12.26 W/m2 Q Ceiling = 8.98 W/m2 Considering a 6000MT Potato Cold Store Dimension 105’ (32M) x 105’(32M) x 60’(18M) (H) Total Area Wall – 1152 m2, Ceiling -1024m2, Floor – 1024 m2. Thermal Transmission Value Q Total (Theoretical) = 24 KW

MODERN PRACTICES IN COLD STORE CONSTRUCTION

MODERN COLD STORES Wall = 80mm PUF Panel Ceiling = 100mm PUF Panel Floor = 60mm EPS Slabs finished with lean concrete

MODERN PRACTICES IN COLD STORE CONSTRUCTION

MODERN COLD STORAGE – PUF Panel 80 / 100mm Thermal Transmission Values Q Wall = 11.00 W/m2 Q Ceiling =

8. 57 W/m2

Q Total = 21 KW 12-15% reduction in heat gain. Initially Energy Savings Rs.13000 per month or Rs.1.60 Lacs per annum. Thereafter Rs.43000 per month or Rs.5-6 Lacs per annum.

EXISTING COLD STORES

Civil Structure / Building Sound Construction
Insulation damaged
Reap of Insulation

REVAMP PROCEDURE

Insulation can be replaced by –

Pre-fab Polyurethane Panels

0.5mm Steel sheet PUF Insulation 1mm Aluminium Foil

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4/2/2012 35

EXISTING COLD STORES

Removal of old insulation & plastering of surface.
Prefab Polyurethane Panels with facing side metal

finish and inner side paper or Aluminium foil finish.

Panels to be directly fixed to the walls with self drilling

fasteners.

Sealing of Panel joints with Silicon Sealant.

REVAMPING OF EXISTING STORES

Replacement of moisture soaked Insulation

Fixing prefab panels with one side metal facing and

paper facing on the walls.

CHATRAKARAN POTATO COLD STORAGE, INDORE (MP)

FIRST MODERN POTATO COLD STORE

1997

SANGHA CHAITANYA COLD STORAGE, KHAMMAM (AP) NEETHI COLD STORAGE, HYDERABAD

SAFAL COLD STORAGE COMPLEX, BANGALORE

SLIDE 36

4/2/2012 36

HINDUSTAN AGRO COOPERATION LTD.

Agro Irradiation Cold Storage at Rahuri, Ahmednagar 25000 MT

PRAGATI COLD STORAGE, KUNDLI

2010

MODERN COLD STORE Future Trend for Construction

THE NEED (Customer’s perspective) Fresh & Safe Produce THE NECESSITY (Grower’s perspective) Good cold chain practices

MODERN COLD CHAIN MANAGEMENT INCREASING LIFE SPAN OF FRESH PRODUCE FROM FARM TO FORK FINALLY

Everyone thinks of changing the world, but no one thinks

f changing himself.

Leo Tolstoy

Pay heed to the calls, before another moment falls PRESENTER

SLIDE 37